Athletic shoe having a segmented upper

ABSTRACT

An athletic shoe having an improved upper, and method of manufacture are presented herein. The upper is generally comprised of a forefoot panel extending over a portion of the sole corresponding to a forward area of a wearer&#39;s foot, a mid-section panel extending over a portion of the sole corresponding to a midfoot area of the wearer&#39;s foot, and a rear panel extending over a portion of the sole corresponding to a rearfoot area of the wearer&#39;s foot. The upper further comprises a first expansion joint joining the forefoot panel to the mid-section panel, and a second expansion joint joining the mid-section panel to the rearfoot panel.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to athletic footwear, and more specifically to an improved upper for an athletic shoe.

2. Background Art

Athletic footwear must provide stable and comfortable support for the foot. Specifically, it is important that the footwear be comfortable while providing adequate support during various foot movements associated with athletic activity. Athletic footwear typically includes an upper and a sole, and is sold in a variety of sizes according to the length and width of the foot. However, even feet of similar length do not have the same geometry. Therefore, a conventional upper must be adjustable to provide support to various foot contours. Many different products and designs have focused on the need for adjustable upper support. For example, the upper may include an ankle portion which encompasses a portion of the ankle region of the foot and thereby provides support thereto. Other products have incorporated air bladders in the upper for adjustable support. The standard upper, however, is typically constructed of one mesh material, with minimal stretch.

In addition, it is well known to adjust the size of a shoe through lacing or through one or more straps reaching across the throat of a typical shoe. Lacing alone, however, suffers from several disadvantages, for example, when the shoe laces or straps are drawn too tightly, the fastening system can cause pressure on the instep of the foot. Such localized pressure is uncomfortable to the wearer and can make it difficult for the shoe to be worn for prolonged periods of time. Furthermore, while lacing allows the upper of the shoe to be adjustable to accommodate varying foot and ankle configurations, it does not mold the shoe to the contour of the foot. Moreover, there are areas of the foot which are not supported by the upper, due to the irregular contour of the foot.

The human foot is a complex bone structure, capable of withstanding and dissipating many impact forces. FIG. 1 shows a skeletal depiction of the foot 100. There are three main divisions to the foot. Portions of the foot include rear foot 102, midfoot 104, and forefoot 106. The rear foot 102 includes the talus 108 and the calcaneus 110. The midfoot 104 includes three cuneiforms 112, cuboid 114 and navicular 116. The forefoot 106 includes metatarsal 118, proximal phalanges 120, and distal phalanges 122.

While the three main divisions of the foot are linked to each other, it is not uncommon for the three main divisions to move relative to each other during athletic activity. Although many products are designed to accommodate the shape of a foot when the foot is static, the problems associated with the fit of an upper during dynamic movement of the foot have not been adequately addressed. Specifically, the standard design of an athletic shoe, which includes only a continuous upper structure, does not provide adequate mobility between the three main divisions of the foot, i.e., rearfoot 102, midfoot 104, and forefoot 106.

BRIEF SUMMARY OF THE INVENTION

Presented herein is an article of footwear having a sole and an upper attached to the sole, wherein the upper is comprised of a forefoot panel extending over a portion of the sole corresponding to a forward area of a wearer's foot, a mid-section panel extending over a portion of the sole corresponding to a midfoot area of the wearer's foot, and a rearfoot panel extending over a portion of the sole corresponding to a rear area of the wearer's foot. The upper further comprises a first expansion joint joining the forefoot panel to the mid-section panel, and a second expansion joint joining the mid-section panel to the rearfoot panel. The first expansion joint and the second expansion joint are formed of a material with a greater stretch characteristic than that of the forefoot panel, mid-section panel, and rearfoot panel. The expansion joints may be formed of a two-way expandable material. Alternatively, the expansion joints may be formed of a four-way expandable material. For example, the expansion joints may be formed of a spandex material, or a spandex material having a polyurethane coating. Further, in one aspect of the invention, an end of the forefoot panel is spaced about 3 to 4 millimeters from a first end of the mid-section panel and a second end of the mid-section panel is spaced about three to four millimeters from an end of the rearfoot panel. Also, in another aspect of the invention, the expansion joints are comprised of a material having a stretch retention of less than about 15%, and more preferably a material having a stretch retention of less than about 5%. The expansion joints may be entirely on a medial side of the article of footwear, entirely on a lateral side of the article of footwear, or extend from a medial side of the article of footwear to a lateral side of the article of footwear.

In accordance with an alternative aspect of the invention, the upper is comprised of a first panel extending over a portion of the sole corresponding to a forward area of the wearer's foot, a second panel extending over a portion of the sole corresponding to a rear area of the wearer's foot with respect to the first panel, wherein the first and second panels are formed of a material having a stretch retention of greater than about 15%, and an expansion joint joining the first panel and second panel, wherein the expansion joint is formed of a material having a stretch retention of less than about 15%. In accordance with an alternative aspect of the invention, the upper is comprised of a stretch material having a stretch retention of less than about 15%, and a non-stretch material overlaying the stretch material, wherein the non-stretch material has a stretch retention of greater than about 15%.

Further disclosed herein is a method for manufacture of an upper for an article of footwear comprising: a) securing a portion of a first expansion joint to a portion of a forefoot panel; b) securing a mid-section panel to a portion of the first expansion joint; c) securing a second expansion joint to a portion of the mid-section panel; and d) securing a rearfoot panel to a second portion of the second expansion. The joints and panels may be secured to one another by being sewn together, by an RF welding technique, or using a zig-zag stitch technique. The upper is then preferably attached to a sole of an athletic shoe. In an alternative method presented herein, a portion of an end of the forefoot panel is spaced about three to four millimeters from a portion of a first end of the mid-section panel, and a portion of a second end of the mid-section panel is spaced about three to four millimeters from a portion of an end of the rearfoot panel.

BRIEF DESCRIPTION OF THE DRAWINGS/FIGURES

The accompanying figures, which are incorporated herein and form part of the specification, illustrate an athletic shoe. Together with the description, the figures further serve to explain the principles of the athletic shoe described herein and thereby enable a person skilled in the pertinent art to make and use the athletic shoe.

FIG. 1 shows a skeletal depiction of the foot.

FIG. 2 shows an athletic shoe having an upper in accordance with one embodiment of the present invention.

FIG. 3 shows an athletic shoe having an upper in accordance with an alternative embodiment of the present invention.

FIG. 4 shows an athletic shoe having an upper in accordance with yet another embodiment of the present invention.

FIG. 5 shows an athletic shoe having an upper in accordance with another embodiment of the present invention.

FIG. 6 shows an athletic shoe having an upper in accordance with still another embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

Preferred embodiments of an athletic shoe are described below with reference to the figures where like reference numbers indicate identical or functionally similar elements. Also in the figures, the left most digit of each reference number corresponds to the figure in which the reference number is used. While specific configurations and arrangements are discussed, it should be understood that this is done for illustrative purposes only. A person skilled in the relevant art will recognize that other configurations and arrangements can be used without departing from the spirit and scope of the appended claims.

FIG. 2 shows an athletic shoe 200. Shoe 200 is comprised of an outsole 202, a midsole 204, and an upper 206. An insole is typically included within the shoe, but is not shown in the figure. Outsole 202 is typically comprised of a wear-resistant rubber material. Midsole 204 is typically comprised of an ethylene-vinyl acetate (EVA) material. Alternatively, midsole 204 may be comprised of alternative materials. The shoe is completed with a tongue portion 208 and shoelaces 210. Tongue portion 208 and shoelaces 210, are optional as would be known to one of skill in the art. Further, the materials comprising outsole 202 and midsole 204 may be chosen as deemed fit by one of skill in the art.

Upper 206, as shown in FIG. 2, is comprised of a forefoot panel 212, a mid-section panel 214, and a rearfoot panel 216. Forefoot panel 212 extends over a portion of the sole corresponding to a forefoot area of the wearer's foot. Mid-section panel 214 extends over a portion of the sole corresponding to a midfoot area of the wearer's foot. Rearfoot panel 216 extends over a portion of the sole corresponding to a rearfoot area of the wearer's foot. Upper 206 also includes a first expansion joint 218. First expansion joint 218 joins forefoot panel 212 to mid-section panel 214. Upper 206 also includes a second expansion joint 220. Second expansion joint 220 joins mid-section panel 214 to rearfoot panel 216. Optionally, a comfort padding 222 is added to upper 206.

The number of panels that comprise upper 206 is not restricted to just three panels. Any number of panels between two and about seven may be used. The objective of the panels is to mimic the relative movement of the different areas of the foot. For that reason, three panels are preferred because the foot is generally divided into three main divisions; specifically the forefoot, midfoot, and rearfoot. In this manner, upper 206 can move with the foot. In a typical shoe, the lack of stretch and mobility in the upper creates relative movement between the foot and the upper, which in turn creates blisters and sore spots. In contrast to a typical shoe, the mobility between panels 212, 214, and 216 in upper 206 works to prevent blisters and sore spots.

The expansion joints are preferably formed of a synthetic material. For example, the expansion joints may be formed of a midbacker coated with polyurethane. The midbacker can be a material such as spandex. Alternatively, the expansion joints may be straight textile spandex. Preferably, the expansion joints are formed of a four-way stretch material. In alternative embodiments the expansion joints may be formed of a two-way stretch material. Further, the expansion joints are preferably formed of a material having a greater stretch characteristic than that of the panels. For example, under an Elastic Gore Retention test, a preferred material for the expansion joints would have a maximum stretch retention of less than 15%, and more preferably a maximum stretch retention of less than 5%.

The expansion joints are typically attached to the panels through a zig-zag stitch between the panels. After stitching, the panels may be overlaid with a synthetic material. In a preferred embodiment, the panels are separated from each other by a gap of about three to four millimeters. In alternative embodiments, the expansion joints may be sewn on, RF welded, or attached to the panels by any other attachment operation known to the art.

FIG. 3 shows an athletic shoe 300, in accordance with an alternative embodiment of the present invention. Shoe 300 is different from shoe 200 of FIG. 2 by having an alternative upper 306. Upper 306 is comprised of forefoot panel 312, mid-section panel 314, and rearfoot panel 316. An expansion joint 318 joins forefoot panel 312 to mid-section panel 314. A second expansion joint 320 joins mid-section panel 314 to rearfoot panel 316. Expansion joint 320 of shoe 300 differs from the expansion joint 220 of shoe 200 in that expansion joint 320 extends from the back of the shoe to the midsole 304. Such an embodiment adds design flexibility, while still functioning in accordance with the objectives of the present invention.

FIG. 4 shows an athletic shoe 400, in accordance with an alternative embodiment of the present invention. Shoe 400 differs from the previously described shoes in that shoe 400 does not include multiple expansion joints. Instead, shoe 400 includes a single expansion joint 424, which is one integral unit that forks in two directions. As such, each panel (forefoot panel 412, mid-section panel 414, and rearfoot panel 416) is attached to a portion of expansion joint 424. In the embodiment shown in FIG. 4, mid-section panel 414 does not correlate exactly with the midfoot, but instead correlates with a portion of the foot between the forefoot panel 412 and the rearfoot panel 416. The design of shoe 400, however, does not depart from the objectives of the present invention. Shoe 400 still allows relative mobility of the individual portions of upper 406, which in turn correspond to the relative movement of the different parts of a wearer's foot.

FIG. 5 shows an athletic shoe 500 in accordance with another embodiment of the present invention. Athletic shoe 500 differs from the previously described shoes in that expansion joint 526 forms one integral unit with a central opening. As such, each panel (forefoot panel 512, mid-section panel 514, and rearfoot panel 516) is attached to a portion of expansion joint 526. Specifically, mid-section panel 514 is disposed within the central opening of expansion joint 526. The design of shoe 500, however, does not depart from the objectives of the present invention. Shoe 500 still allows relative mobility of the individual portions of upper 506, which in turn correspond to the relative movement of the different parts of a wearer's foot.

FIG. 6 shows an athletic shoe 600 in accordance with another embodiment of the present invention. Athletic shoe 600 differs from the previously described shoes in design, but not in function. The alternative design of shoe 600 does not depart from one objective of the present invention; that being to provide a kinetic fit for a shoe that provides adequate support while also providing adequate flexibility to mirror the movement of the various skeletal sections of a user's foot. Shoe 600 comprises an upper 606 formed of a stretch mesh material 630 extending throughout the shoe. A non-stretch synthetic material 640, such as for example a synthetic leather, is provided throughout the upper to provide adequate support. In one embodiment, non-stretch material 630 is laid over stretch mesh material 630 and attached to stretch mesh material 630 by conventional means. In one embodiment, non-stretch material 640 has a plurality of “fingers” 642 that extend upward from the bottom of upper 606. In between fingers 642 is stretch material 630. As such, stretch material 630 serves as expansion joints between fingers 642.

The shoes described above may be manufactured by a method comprising: a) securing a portion of a first expansion joint to a portion of a forefoot panel; b) securing a mid-section panel to a portion of the first expansion joint; c) securing a second expansion joint to a portion of the mid-section panel; and d) securing a rearfoot panel to a second portion of the second expansion. The panels may be secured to one another by being sewn together, by an RF welding technique, or using a zig-zag stitch technique. The upper is then preferably attached to a sole of an athletic shoe. In an alternative method presented herein, a portion of an end of the forefoot panel is spaced about three to four millimeters from a portion of a first end of the mid-section panel, and a portion of a second end of the mid-section panel is spaced about three to four millimeters from a portion of an end of the rearfoot panel.

The shoes described above may also be manufactured by the alternative method of: a) providing one unitary upper formed of a stretch material; and b) securing onto the stretch material a second material, which is less stretchable than said stretch material.

Although it is acknowledged that all materials are stretchable to a certain extent, as used herein the terms “stretch material,” “stretchable material,” “non-stretch material,” and “non-stretchable material” are terms of art. More specifically, the term “stretch” or “stretchable” is intended to refer to materials which have a maximum stretch retention of less than 15%, and more preferably a maximum stretch retention of less than 5%, under an Elastic Gore Retention test. In such a test, a swatch of material is first measured in an unloaded and neutral state. The material is then stretched or extended to, for example, one and a half times its original length and/or width. The material is then measured again in an unloaded and neutral state. The second measurement is intended to determine the material's ability to return to its original size. A material that returns to within 15% of its original size, may be considered a “stretch” or “stretchable” material. However, materials that either fail during extension, or do not return to within 15% of its original size, may be considered a “non-stretch” or “non-stretchable” material.

While various embodiments of an athletic shoe have been described, it should be understood that they have been presented by way of example, and not limitation. For example, the illustrated design and direction of the expansion joints were not intended to be limiting. Further, the forefoot, mid-section, and rearfoot panels may take on any form or configuration desirable to a designer. Further, the terms “forefoot,” “mid-section,” “midfoot,” and “rearfoot” are not intended to be limited to the exact bone structure of a wearer's foot, or the bone structure shown in FIG. 1. Instead, the terms are used solely to designate a forward area of the foot, a middle area of the foot, and a rear area of the foot, respectively. Also, FIGS. 2-6 show a medial view of an athletic shoe. It would be apparent to one of skill in the art that a lateral view of the athletic shoe would be the mirror image of that shown. In alternative embodiments, however, expansion joints can be included in the medial side of the shoe only, the lateral side of the shoe only, or both the medial and lateral side of the shoe. The number, location, design, and direction of the expansion joints may be altered in any fashion as would be deemed fit by a designer. Further, although an athletic shoe is described, the presented invention and methods may be employed in any article of footwear such as a boot, dress shoe, sandal, etc.

It will be apparent to a person skilled in the relevant art that various changes in form and detail can be made therein without departing from the spirit and scope of the appended claims. Thus the present invention should not be limited by any of the above-described exemplary embodiments, but should be defined only in accordance with the following claims and their equivalents. 

1. An article of footwear having a sole and an upper attached to the sole, wherein the upper is comprised of: a forefoot panel extending over a portion of the sole corresponding to a forward area of a wearer's foot; a mid-section panel extending over a portion of the sole corresponding to a midfoot area of the wearer's foot; a first expansion joint joining the forefoot panel to the mid-section panel; a rearfoot panel extending over a portion of the sole corresponding to a rear area of the wearer's foot; and a second expansion joint joining the mid-section panel to the rearfoot panel; wherein the first expansion joint and the second expansion joint are formed of a material with a greater stretch characteristic than that of the forefoot panel, mid-section panel, and rearfoot panel.
 2. An article of footwear as defined in claim 1, wherein one of the expansion joints comprises a two-way expandable material.
 3. An article of footwear as defined in claim 1, wherein one of the expansion joints comprises a four-way expandable material.
 4. An article of footwear as defined in claim 1, wherein one of the expansion joints comprises a spandex material.
 5. An article of footwear as defined in claim 1, wherein one of the expansion joints comprises a spandex material having a polyurethane coating.
 6. An article of footwear as defined in claim 1, wherein an end of the forefoot panel is spaced about 3 to 4 millimeters from a first end of the mid-section panel and a second end of the mid-section panel is spaced about three to four millimeters from an end of the rearfoot panel.
 7. An article of footwear as defined in claim 1, wherein one of the expansion joints is comprised of a material having a stretch retention of less than about 15%.
 8. An article of footwear as defined in claim 1, wherein one of the expansion joints is comprised of a material having a stretch retention of less than about 5%.
 9. An article of footwear as defined in claim 1, wherein one of the expansion joints is entirely on a medial side of the article of footwear.
 10. An article of footwear as defined in claim 1, wherein one of the expansion joints is entirely on a lateral side of the article of footwear.
 11. An article of footwear as defined in claim 1, wherein one of the expansion joints extends from a medial side of the article of footwear to a lateral side of the article of footwear.
 12. An article of footwear having a sole and an upper attached to the sole, wherein the upper is comprised of: a first panel extending over a portion of the sole corresponding to a forward area of the wearer's foot; a second panel extending over a portion of the sole corresponding to a rear area of the wearer's foot with respect to the first panel, wherein the first and second panels are formed of a material having a stretch retention of greater than about 15%; and an expansion joint joining the first panel and second panel, wherein the expansion joint is formed of a material having a stretch retention of less than about 15%.
 13. An article of footwear as defined in claim 12, wherein the expansion joint comprises a two-way expandable material.
 14. An article of footwear as defined in claim 12, wherein the expansion joint comprises a four-way expandable material.
 15. An article of footwear as defined in claim 12, wherein the expansion joint comprises a spandex material.
 16. An article of footwear having a sole and an upper attached to the sole, wherein the upper is comprised of: a stretch material having a stretch retention of less than about 15%; and a non-stretch material overlaying the stretch material, wherein the non-stretch material has a stretch retention of greater than about 15%.
 17. An article of footwear as defined in claim 16, wherein the stretch material is a two-way expandable material.
 18. An article of footwear as defined in claim 16, wherein the stretch material is a four-way expandable material.
 19. An article of footwear as defined in claim 16, wherein the stretch material is a spandex material.
 20. A method for manufacture of an upper for an article of footwear, comprising: securing a portion of a first expansion joint to a portion of a forefoot panel; securing a mid-section panel to a portion of the first expansion joint and a first portion of a second expansion joint; and securing a second expansion joint to a portion of the mid-section panel; and securing a rearfoot panel to a second portion of the second expansion.
 21. A method according to claim 20, wherein the panels are secured respectively by being sewn together.
 22. A method according to claim 20, wherein the panels are secured respectively by an RF welding technique.
 23. A method according to claim 20, wherein the panels are secured respectively using a zig-zag stitch technique.
 24. A method according to claim 20, further comprising attaching the upper to a sole.
 25. A method according to claim 20, wherein a portion of an end of the forefoot panel is spaced about three to four millimeters from a portion of a first end of the mid-section panel, and a portion of a second end of the mid-section panel is spaced about three to four millimeters from a portion of an end of the rearfoot panel. 